2007 Harley-Davidson Softail Service Manual (P/N 99482-07)

Harley-Davidson’s 2007 Softail Service Manual, P/N 99482-07, carries a 2006 copyright and covers FXST, FXSTB, FXSTC, FXSTD, FLSTC, FLSTF, FLSTN and FLSTSC models.

• Engine repair: Compression and cylinder-leakage testing, top-end and crankcase overhaul, cam support plate service, oil-pump inspection and counterbalancer assembly work.
• Clutch and transmission: Clutch-pack replacement, primary-drive service, transmission disassembly and assembly, shift-fork inspection, and main drive gear and bearing replacement.
• Chassis and suspension: Wheel lacing and truing, sealed wheel-bearing replacement, brake repair, hydraulic-fork rebuilding and FLSTSC Springer fork service.
• Fuel and emissions: Fuel-pressure and intake-leak tests, injection-component replacement, model-specific exhaust procedures, and California evaporative-emissions system service.
• Electrical components: Starter overhaul and component tests, alternator and regulator replacement, TSM/TSSM/HFSM service, wiring diagrams and connector repair.
• Service references: Maintenance schedules, component-specific torque tables, service wear limits and specialty-tool references accompany the repair procedures.

The manual supports basic maintenance and repair, while its major repair methods are written for professional Harley-Davidson technicians and call for specialized shop equipment.

Engine Testing and Internal Repair

Engine coverage runs from compression, cylinder-leakage and oil-pressure tests to cylinder-head work, piston and cylinder inspection, and crankcase overhaul. The diagnostic material connects test findings with possible causes of oil consumption or poor compression, helping narrow the problem before disassembly.

Counterbalancer procedures cover timing, sprocket alignment and bearing replacement. The flywheel and connecting rods are inspected as an assembly; replacement of the flywheel, connecting rods or right-side bearing inner race requires replacement of the complete flywheel assembly.

The balance-shaft section warns that a detached retention-pin tip left inside the engine can cause severe engine damage.

Primary Drive, Clutch and Transmission

Clutch procedures cover disc inspection and replacement, shell and hub service, and release-mechanism adjustment. Transmission work extends to the mainshaft, countershaft, shift forks, side-door bearings and main drive gear.

The clutch hub mainshaft nut has a left-hand thread; the transmission sprocket nut has a right-hand thread. The primary-drive procedures specify locking tool HD-47977 and warn that using the older HD-41214 tool can damage components.

Springer and Hydraulic Front Ends

The front-end chapters distinguish the FLSTSC Springer fork from the hydraulic forks. Separate hydraulic-fork configurations apply to FLSTC/FLSTF/FLSTN, FXST/FXSTB/FXSTC and FXSTD, helping you select the appropriate assembly drawing and service procedure.

Coverage includes Springer rocker-bearing inspection, steering-head bearing adjustment and hydraulic-fork oil replacement. Wheel lacing and truing, sealed wheel-bearing replacement, and brake caliper and master-cylinder repair are also documented.

The motorcycle must be securely supported for wheel, suspension and other chassis work.

Fuel Injection and Emissions Equipment

Fuel-system procedures cover the induction module, injectors, pump, filter and pressure regulator, along with Idle Air Control (IAC) and oxygen-sensor replacement. HDI active intake and active exhaust equipment and California evaporative-emissions components receive separate coverage.

Diagnostic scope: Fuel-pressure testing is included, but detailed EFI and sensor diagnosis is assigned to the separate Softail Models Electrical Diagnostic Manual, which is not included.

Electrical Service and Wiring References

Starter repair includes armature, field-winding and brush-holder tests. Electrical chapters cover alternator, regulator and wiring-harness replacement, plus the functions and replacement of TSM/TSSM/HFSM modules. Security password learning and key-fob assignment require the separate electrical diagnostic manual.

Exploded assembly views accompany the repair sections. Reference graphics include the EFI System Circuit, Engine Oil Flow: Top End, Drive Belt Wear Analysis, the California evaporative-emissions schematic, and starting and charging circuit diagrams. Connector-location tables and terminal-repair instructions support wiring work.

Examples of Plug-Gap and Belt-Deflection Specifications

Spark-plug inspection specifies an electrode gap of 0.038–0.043 in. (0.97–1.09 mm).

For FLSTN and FXSTD, the rear-belt table lists 1/4–5/16 in. (6.4–7.9 mm) deflection with the motorcycle cold, on its jiffy stand and without rider or luggage. The specification uses a 10 lb. (4.5 kg) test force at the belt’s tightest point.

Searchable Text, Bookmarks and Wiring Pages

Search and diagram navigation: OCR text supports searching, though recognition errors can affect exact terms. Bookmarks link to the eight main sections, Appendices A and B, and the index; the Contents bookmark opens the title page. Wiring diagrams extend across multiple PDF pages, and small pin numbers and wire-color labels require zooming.

One printable English PDF contains 652 pages, including 15 pages of title and introductory material, six Notes pages and one repeated charging-circuit page. The appendices and index are included in that total.